Curved ceiling panel

ABSTRACT

A curved suspension ceiling panel that creates the appearances of a curved or wavy ceiling surface when used in combination with a planar grid system. The curved suspension ceiling panel comprises a curved exterior surface. The curved panel includes a pair of opposed sidewalls that are attached to the curved exterior surface and includes a curved surface along a first edge and a substantially linear surface along a second edge. The linear edges include a flange that permits the panel to be attached to grid members of a planar grid system. The curved panels are designed so that they can be inverted within the grid so that the curved exterior surface is above the grid members. During installation, the curved panels can be arranged to form an undulating or wavy pattern to create a desired effect when viewed from below.

BACKGROUND

This disclosure relates to suspended ceiling systems and moreparticularly to a novel and improved system using curved ceiling panelshaving a curved exterior surface in combination with a planar perimeterthat is adapted to be used with a horizontal grid structure.

By way of background but not limitation, suspended ceiling systemstypically include grid members that provide for oppositely extendingceiling panel support flanges. In these systems, the edges of theceiling panels are installed by laying them in the panel opening createdby the grid members. There are also suspended-ceiling systems that havegrid members, which include channels designed to grip the verticallyextending edges of metal ceiling panels. These ceiling panels aretypically installed by snapping the flanges up into the grid memberchannel, and are generally referred to as “snap-up ceiling panels.”Typical lay-in grid panels are manufactured to fit within a horizontalgrid and are planar in nature. In order to obtain a curved ceilingsurface in typical ceiling systems, curved panels are used incombination with curved ceiling grid members. The use of curved gridmembers to form the ceiling structure increases cost and difficulty ofinstallation.

In view of the above, it should be appreciated that there is a need fora ceiling system that provides for a curved ceiling surface whilepermitting the use of a standard horizontal grid arrangement. Thepresent disclosure satisfies these and other needs and provides furtherrelated advantages.

SUMMARY

The disclosure may be described as a novel and improved curvedsuspension ceiling system that creates the appearance of a curved orwavy ceiling surface when used in combination with a planar grid system.In the preferred embodiment, the curved panel system comprises ametallic or polymer curved panel having a curved exterior surface formedby a curved wall. The curved panel includes a pair of opposed sidewallsthat are attached to the curved wall and include a curved surface alonga first edge and a substantially linear surface along a second edge. Thelinear edges each include flanges that permit the curved panel to beattached to grid members of the planar grid system. The curved panelsare designed so that they can be flipped over so that the face of thecurved wall can be oriented to face above or below the ceiling grid.During installation, the curved panels can be alternately flipped toform an undulating or wavy pattern to create a desired effect whenviewed from below.

Other features and advantages of the disclosure will be set forth inpart in the description which follows and the accompanying drawings,wherein the embodiments of the disclosure are described and shown, andin part will become apparent upon examination of the following detaileddescription taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above mentioned and other features of this disclosure and the mannerof obtaining them will become more apparent and the disclosure will bebest understood by reference to the following description of embodimentsof the disclosure taken in conjunction with the accompanying drawings inwhich:

FIG. 1 is a perspective view of a ceiling system illustrating curvedceiling panels;

FIG. 2 is a sectional view of the ceiling system, taken along lines 2-2,illustrating the curved ceiling panels connected to a grid system;

FIG. 3 is a perspective view of the curved ceiling panel;

FIG. 4 is a top view of the curved ceiling panel;

FIG. 5 is a side elevational view of the curved ceiling panel; and

FIG. 6 is an end view of the curved ceiling panel.

DETAILED DESCRIPTION

While the present disclosure will be described fully hereinafter withreference to the accompanying drawings, in which a particular embodimentis shown, it is to be understood at the outset that persons skilled inthe art may modify the disclosure herein described while still achievingthe desired result. Accordingly, the description that follows is to beunderstood as a broad informative disclosure directed to persons skilledin the appropriate art and not as limitations on the present disclosure.

As illustrated in the drawings, FIG. 1 illustrates a portion of anassembled suspension ceiling incorporating curved ceiling panels 10 inaccordance with the present disclosure. In such a ceiling panel system,grid members 12 are interconnected to form a grid structure 13. The gridmembers 12 are arranged to form openings sized to receive the curvedceiling panels 10. The grid members 12 are suspended from the buildingstructure by wire hangers 16 or other supporting structures.

To create the grid structure 13, a row of parallel evenly spaced gridmembers 12 are suspended by the wire hangers 16. Each row of the gridmembers 12 are spaced apart to accommodate the size of the curvedceiling panels 10. To accommodate a two foot by two foot ceiling panel,the grid members 12 would be spaced apart two feet on-center. The gridstructure 13 also includes a second set of grid members 18 that areperpendicularly oriented in relation to the first set of grid members 12to create the opening required for hanging the curved ceiling panels 10.

The curved ceiling panels 10 are normally rectangular or square inshape, and are preferably made out of metal or polymer. The curvedceiling panels 10 are durable in that they are impact resistant,self-supporting do not sag when spanned between grid members 12. Metaland plastic polymeric material, such as polycarbonate, are preferredsince panels can be molded or stamped to include a desired shape or toform various edge configurations for connection to the grid structure13. Alternately, among other rigid, and semi-rigid materials, glassreinforces gypsum, wood or thermoformed fabrics may be used.

The curved ceiling panel 10 used within the grid structure 13 as shownin FIGS. 1 and 2 are comprised of a curved wall 20 that includes a firstface 22 and second face 24, opposing the first face 22. Depending uponthe orientation of the curved panels 10 within the grid structure 13,either the first face 22 or the second face 24 may be exposed to thearea below the grid structure 13. The curved wall 20 of the curvedceiling panel 10 is curved about its length and extends from a firstedge 26 to a second edge 28 of the curved ceiling panel 10. The curvedceiling panels 10 also includes a first sidewall 30 and a spaced apartsecond sidewall 32. The first sidewall 30 is substantially parallel tothe second sidewall 30.

The first sidewall 30 of the curved ceiling panel 10 includes arelatively linear edge 34 and a curved edge 36. The curved edge 36 ofthe first sidewall 30 is spaced apart from the linear edge 34 in thecentral region of the panel 10 but converges with the linear edge 34 atthe endpoints 38 of the curved edge 36. The curved edge 36 is formed bythe intersection of the curved wall 20 with the first sidewall 30.

The second sidewall 32 of the panel 10 is parallel to and spaced apartfrom the first sidewall 30. The second sidewall 32 of the panel 10includes a relatively linear edge 40 and a curved edge 42 as shown inFIG. 5. The curved edge 42 of the second sidewall 32 is spaced apartfrom the linear edge 40 in the central region of the panel 10 butconverges with the linear edge 40 at the endpoints 44 of the curved edge42. The curved edge 42 is formed by the intersection of the curved wall20 with the second sidewall 32.

The first and second edges 26, 28 of the panel 10 form a portion of theperimeter of the panel 10. The first edge 26 includes a first flange 46that extends outwardly from the panel 10. The first flange 46 is adaptedto be connected to the grid members 12 of the grid structure 13 to aidin supporting the panel 10. In a lay-in panel arrangement, the firstflange 46 is horizontally oriented and rests upon a base portion 58 ofthe grid members 12 as shown in FIG. 2. When using a snap-in panelarrangement, the first flange 46 is adapted to be connected to a channelportion of the grid members 12. The second edge 28 includes a secondflange 48 that extends outwardly from the panel 10. The second flange 48is adapted to be connected to the grid members 12 of the grid structure13 to aid in supporting the panel 10 as shown in FIG. 4.

The linear edge 34 of the first sidewall 30 of the curved panel 10includes a third flange 50 that extends outwardly from the curved panel10 as shown in FIG. 3. The third flange 50 is adapted to be connected tothe grid members 12 of the grid structure 13 to aid in supporting thepanel 10. The linear edge 40 of the second sidewall 32 includes a fourthflange 52 that extends outwardly from the curved panel 10. The first,second, third and fourth flanges 46, 48, 50 and 52 form the perimeter ofthe curved ceiling panel 10. The flanges 46, 48, 50 and 52 may alsoinclude tabs that aid in retaining the curved ceiling panels 10 to thegrid structure 13.

The curved ceiling system, as shown in FIGS. 1 and 2, illustrates thecurved panels 10 connected to the grid structure 13 by use of flanges46, 48. While the curved ceiling panels 10 preferably are connected tothe grid structure 13 with flanges, a hinge may be used to permit thecurved ceiling panel 10 to be pivoted to an open position for serviceabove the ceiling structure 13. While flanged edges and a hinged edgeare disclosed, other edge configurations may be used to secure thecurved ceiling panels 10 to the grid system 13. It is beneficial to usethe hinge to support the curved ceiling panel 10 when all metal ceilingpanels become as large as 4 feet by 4 feet, because the panels becomeawkward to install and remove due to their relatively large size andweight. Further illustrations of the use of a hinge can be found in U.S.Pat. No. 6,467,228, incorporated herein by reference. When working witha piece of sheet metal with such a large surface, any improper handlingmay result in damage to the overall finish of the ceiling panel 10.Also, by using the hinge that spans the width of the curved ceilingpanel 10, the weight of the panel is evenly distributed across theentire edge of the curved panel 10, preventing rippling that would beapparent in the curved wall 20 of the curved panel 10. Furthermore, oncethe curved ceiling panel 10 is connected to the grid members 12, thecurved ceiling panel 10 will automatically be in alignment to allow foreasy closure by pivoting the ceiling panel 10 upward and snapping in theflanges into the grid.

The grid member 12, as shown in FIG. 2, in this example 12 is fabricatedout of die-formed sheet metal. The grid member 12 after fabricationincludes a bulb portion 56, a base portion 58 and a bridge portion 60that connects the bulb portion 56 and the base portion 58. The overallshape of the grid member 12 is to give the member 12 strength to preventflexing. Typically, apertures (not shown) are placed along the length ofthe bridge portion 60 so that wire hangers 16 can be threaded throughand wrapped around the bulb portion 56. Once the wire hanger 16, asshown in FIG. 1, which can be in the form of a wire, is threaded throughan aperture (not shown) and around the bulb portion 56, the wire hanger16 is wrapped around itself several times to prevent it from unraveling.

The bridge portion 60 typically includes slots (not shown) that allowone grid member 12 to be connected to the second grid member 18 to formthe grid structure 13. The base portion 58, as shown in FIG. 2 is formedby bending the double layers of the bridge portion 60, ninety degreesoutward and one hundred eighty degrees inward to form a planar surface.If a hinge is used, a modified grid member 12 is used that includes aboxed channel located on the bottom portion of the grid member 12. Thehinge is formed in the curved ceiling panel 10 by die-forming the hingeninety degrees upward to create an upwardly extending leg and thendie-forming the edge ninety degrees inward to create an inward lip. Theinward lip of the hinge rests within the channel of the grid member 12.The flanges 46, 48, 50, 52, shown in FIG. 2, are formed by die-formingor molding the edges 34, 36, 40, 42 of the curved ceiling panel 10outward to form a horizontal surface. The ceiling panel 10 is retainedto the grid structure 13 by positioning the flanges 46, 48, 50, 52 onthe base portion 58 of the grid members.

The environmental area of the building structure is defined as the spacewithin a building used by occupants to work or conduct other activities.It is the inhabitable space within a structure. From the environmentalarea, the curved wall 20 of the curved ceiling panel 10 is substantiallyexposed and viewable by the occupants below. Depending upon theorientation of the curved ceiling panel 10 within the grid structure 13,either the first face 22 or the second face 24 will be viewable from theenvironmental area below. When the curved ceiling panel 10 is positionedwith the curved wall 20 in an arched position, the first face 22 isviewable from below. When the curved ceiling panel 10 is positionedwithin the grid structure 13 with the curved wall 20 in an inverted archposition, the second face 24 of the curved wall 20 is viewable from theenvironmental area below.

The curved ceiling panels 10 are designed with four edges that areadapted to be connected to the grid structure 13. The curved ceilingpanels 10 can be connected to the grid structure 13 using various edgeconfigurations. The edges can be outfitted with flanges that permiteither snap in or lay in configurations.

In use the curved ceiling panels 10 are an economical solution toachieving a unique ceiling appearance. The present arrangement permitsthe creation of a wavy or rolling ceiling appearance while utilizingeasy to install planar grid structure 13. Using the curved ceilingpanels various patterns can be formed in the ceiling including havingall panels oriented in an arched position or all panels oriented in aninverted arch position. Alternating the orientation of the panels inadjacent grid openings permits the creation of wavy or rolling patterns.Since standard linear grid members can be used additional hardware tosecure the proper orientation of the panels with respect to the gridstructure 13 is not required. In systems where curved grid members areused, it is necessary to use additional fasteners to ensure the panelsconform to the shape of the grid members.

While the concepts of the present disclosure have been illustrated anddescribed in detail in the drawings and foregoing description, such anillustration and description is to be considered as exemplary and notrestrictive in character, it being understood that only the illustrativeembodiments have been shown and described and that all changes andmodifications that come within the spirit of the disclosure are desiredand protected.

There are a plurality of advantages that may be inferred from thepresent disclosure arising from the various features of the apparatus,systems and methods described herein. It will be noted that alternativeembodiments of each of the apparatus, systems, and methods of thepresent disclosure may not include all of the features described yetstill benefit from at least some of the inferred advantages of suchfeatures. Those of ordinary skill in the art may readily devise theirown implementations of an apparatus, system, and method that incorporateone or more of the features of the present disclosure and fall withinthe spirit and scope of the invention as defined by the appended claims.

1. A suspended curved panel ceiling system for connection to a structurecomprising: a plurality of linear grid members intersecting to form ahorizontal grid; a plurality of curved panels adapted to be connected tosaid grid, said curved panels having a first upwardly extending side anda second upwardly extending side interconnected by a curved wall, saidcurved wall having a first face and a second face, said first and secondsides each having a curved edge and a substantially linear edge; firstand second flanges formed along the substantially linear edges of eachof said sides, said first and second flanges adapted to support saidcurved panels within said horizontal grid.
 2. The suspended curved panelceiling system of claim 1, wherein the curved wall terminates at a firstedge and a second edge.
 3. The suspended curved panel ceiling system ofclaim 2, wherein the first and second edges each include third and forthflanges formed along the first and second edges, said third and forthflanges adapted to support said curved panels within said horizontalgrid.
 4. The suspended curved panel ceiling system of claim 1, whereinsaid first and second flanges include tabs adapted to support and retainthe position of the curved panels within said horizontal grid.
 5. Thesuspended curved panel ceiling system of claim 1, wherein said curvedpanels are oriented in a first position within the horizontal gridwherein said first face of said curved wall is viewable from below saidhorizontal grid
 6. The suspended curved panel ceiling system of claim 1,wherein said curved panels are oriented in a second position within thehorizontal grid wherein said second face of said curved wall is viewablefrom below said horizontal grid.
 7. The suspended curved panel ceilingsystem of claim 1, wherein said curved panel is fabricated from metal.8. The suspended curved panel ceiling system of claim 1, wherein saidcurved panel is fabricated from a polymer.
 9. A suspended curved panelceiling system for connection to a structure comprising: a plurality oflinear grid members intersecting to form a horizontal grid; a pluralityof curved panels adapted to be connected to said grid, said curvedpanels having a first upwardly extending side and a second upwardlyextending side interconnected by a curved wall, said curved wall havinga first face and a second face, said first and second sides each havinga curved edge and a substantially linear edge; snap-in flanges formedalong the substantially linear edges of each of said sides, said snap-inflanges adapted to support said curved panels within said horizontalgrid.
 10. The suspended curved panel ceiling system of claim 9, whereinsaid curved ceiling panel further includes a hinge adapted to beconnected to said linear grid members and adapted to permit said curvedceiling panel to be pivoted from a closed position to an open positionwithout requiring removal of said curved ceiling panel from said grid.11. A curved ceiling panel for use with a suspended ceiling, said curvedceiling panel comprising: a curved wall having a first face and a secondface; a first upwardly extending sidewall, adjacent to said curved wall,said first sidewall having a curved edge and a substantially linearedge; a second upwardly extending sidewall, adjacent to said curved walland opposing said first sidewall, said first sidewall and said secondsidewall are interconnected by said curved wall, said second sidewallhaving a curved edge and a substantially linear edge; a firstsubstantially linear flange extending outwardly from said linear edge ofsaid first sidewall; a second substantially linear flange extendingoutwardly from said linear edge of said second sidewall.
 12. The curvedceiling panel of claim 11, wherein said curved wall having a pair ofedges terminating in a plane passing through said first and secondlinear flanges.
 13. The curved ceiling panel of claim 12, wherein saidedges of said curved wall each include a substantially linear flange.14. The curved ceiling panel of claim 13, wherein said flanges areinterconnected to form the perimeter of said curved ceiling panel. 15.The curved ceiling panel of claim 13, wherein said flanges all lie in acommon plane.
 16. The curved ceiling panel of claim 11, wherein saidcurved ceiling panel is fabricated out of metal.
 17. The curved ceilingpanel of claim 11, wherein said curved ceiling panel is fabricated outof a polymer.
 18. A curved ceiling panel for use with a suspendedceiling, said curved ceiling panel comprising: a curved wall having afirst face and a second face; a first upwardly extending sidewall,adjacent to said curved wall, said first sidewall having a curved edgeand a substantially linear edge; a second upwardly extending sidewall,adjacent to said curved wall and opposing said first sidewall, saidfirst sidewall and said second sidewall are interconnected by saidcurved wall, said second sidewall having a curved edge and asubstantially linear edge; snap-in flanges formed along said edges ofsaid panel, said snap-in flanges adapted to support said curved panelswithin said horizontal grid.
 19. The curved ceiling panel of claim 18,wherein said curved ceiling panel includes a hinge located along an edgeof the curved ceiling panel.
 20. A suspended curved panel ceiling systemfor connection to a structure comprising: a plurality of linear gridmembers intersecting to form a horizontal grid, said linear grid membershaving a horizontal member and a vertical member; a plurality of curvedceiling panels having an arcuate wall extending from a first edge to asecond edge of said curved ceiling panels, said arcuate wall having afirst face and a second face; a first sidewall connected to said arcuatewall, where said interconnection of said first sidewall with saidarcuate wall forms a curved edge, said first sidewall extending awayfrom said first face of said arcuate wall and having a third edgeperpendicularly oriented to said first and second edges, said third edgeincluding a substantially linear flange adapted to be connected to saidgrid members; a second sidewall connected to said arcuate wall, wheresaid interconnection of said second sidewall with said arcuate wallforms a curved edge, said second sidewall extending away from said firstface of said arcuate wall and having a fourth edge perpendicularlyoriented to said first and second edges and parallel to said third edge,said fourth edge including a substantially linear flange adapted to beconnected to said grid members.
 21. The suspended curved panel ceilingsystem of claim 20, wherein said first and second edges of said curvedceiling panel each include a substantially linear flange adapted to beconnected to said grid members.
 22. The suspended curved panel ceilingsystem of claim 20, wherein said flanges include tabs adapted to supportand retain the position of the curved panels within said horizontalgrid.
 23. The suspended curved panel ceiling system of claim 20, whereinsaid curved panels are oriented in a first position within thehorizontal grid wherein said first face of said arcuate wall is viewablefrom below said horizontal grid.
 24. The suspended curved panel ceilingsystem of claim 20, wherein said curved panels are oriented in a secondposition within the horizontal grid wherein said second face of saidarcuate wall is viewable from below said horizontal grid.
 25. Thesuspended curved panel ceiling system of claim 20, wherein said curvedpanel is fabricated from metal.
 26. The suspended curved panel ceilingsystem of claim 20, wherein said curved panel is fabricated from apolymer.
 27. A suspended curved panel ceiling system for connection to astructure comprising: a plurality of linear grid members intersecting toform a horizontal grid, said linear grid members having a horizontalmember and a vertical member; a plurality of curved ceiling panelshaving an arcuate wall extending from a first edge to a second edge ofsaid curved ceiling panels, said arcuate wall having a first face and asecond face; a first sidewall connected to said arcuate wall, where saidinterconnection of said first sidewall with said arcuate wall forms acurved edge, said first sidewall extending away from said first face ofsaid arcuate wall and having a third edge perpendicularly oriented tosaid first and second edges, said third edge including a snap-in flangeadapted to be connected to said grid members; a second sidewallconnected to said arcuate wall, where said interconnection of saidsecond sidewall with said arcuate wall forms a curved edge, said secondsidewall extending away from said first face of said arcuate wall andhaving a fourth edge perpendicularly oriented to said first and secondedges and parallel to said third edge, said fourth edge including asnap-in flange adapted to be connected to said grid members.
 28. Thesuspended curved panel ceiling system of claim 27, wherein said curvedceiling panel further includes a hinge adapted to permit said curvedceiling panel to be pivoted from a closed position to an open positionwithout requiring removal of said curved ceiling panel from said grid.